Continuous process for producing decaffeinated beverage extract



Jan. 2, 1968 NUTTlNG ET AL 3,361,571

CONTINUOUS PROCESS FOR PRODUCING DECAFFEINATED BEVERAGE EXTRACT Filed Oct. 19, 1964 6 Sheets-Sheet 1 ROAST GROUND C r :DEcAF'FE-lklA iD COMTIMUOLJS EXTRACTION ousous EXTRACT WASH LI UOR. .AMD

1%EssuRE E m :r A ueous ExrmAcT PREsSuRE EXTRACT I com-lmuous 'PieEsSuRE WAsH WA'I-ER...

PRQES$ WATIE [4 I cou'nwucus WASHIUQ 5P1 u-r Col-rt: GROUNDS INVENTORS Lee Nuffing George 5. Chang 5 @za p Attorneys Jan. 2, 1968 L. NUTTING ET AL CONTINUOUS PROCESS FOR PRODUCING DECAFFEINATEID BEVERAGE EXTRACT Filed Oct. 19, 1964 6 SheetsSheet 5 Cum/7:4 r/ou A/asmma Pursue: E/(FIZALYIOM IJA F g. 3A

INVENTORS Lee Nufling George 5. Chang Attorneys Jan. 2, 1968 UTTmg ET AL 3,361,571

CONTINUOUS PROCESS FOR PRODUCING DECAFF'EINATED BEVERAGE EXTRACT Filed Oct. 19, 1964 6 Sheets-Sheet 4 1: M me /5fi vfifi i M H /52 41x l l is. =1 0 0 I 2 7 F l g:

m INVENTORS Lee Nuffing George 5. Chang 5 %& @2409 Attorneys Jan. 2, 1968 1.. NUTTING ET AL 3,361,571

CONTINUOUS PROCESS FOR PRODUCING DECAFFEINATED BEVERAGE EXTRACT Filed 001;. 19, 1964 I 6 Sheets-Sheet 5 E. A a u furs/247w? E v4 Pa/eAr-me .SoAvEA/T Ks C A III/N:- [zrRA crmz Euro/enrol? (OPf/ONAL) I INVENTORS Fl Count-ABATE Lee Nurfing George 5. Chang Attorneys S TEA n Jan. 2, 1968 1.. NUTTING ET AL 3,361,571

CONTINUOUS PROCESS FOR PRODUCING DECAFFEINATED BEVERAGE EXTRACT Filed Oct. 19, 1964 6 Sheets-Sheet 6 Fig. 4

1 END EXMT'IQMT v lfi Muos TO Mull,

7 WASTE Canal MTRA'I'IOIO OP'nowAL 2ND 'Przessums Exw-mcrxou I 'Removl. CAm-zm:

I l l l l l I a l SPENT GIOuuDS To WASTE j| g 'Pmnuc-r INVENTORS Lee Nuffing George 5. Chang 59% @z w v Attorneys United States Patent 3,351,571 CONTINUOUS PROCESS FOR PRODUCING DECAFFEINATED BEVERAGE EXTRACT Lee Netting, Berkeley, and George S. Chung, Kensington, Calif assignors to Hills Bros. Cofiee Inc., San Francisco, Calif, a corporation of California Filed Oct. 19, 1964, Ser. No. 404,769 11 Claims. (CI. 99-70) ABSTRACT OF THE DISCLOSURE A continuous method for recovering decaffeinated soluole coffee extract from roast ground coffee in successive stages of concurrent aqueous extractions, first at atmospheric pressure and then at higher pressure. The aqueous extracting media flows countercurrent to the coffee feed, although each stage is concurrent. Feed water first washes multiple-extracted grounds to pick up residual coffee values, the liquor serves to extract soluble components in the pressure stage or stages and finally the liquor extracts in the atmospheric stage or stages to give the final aqueous extract from which caffeine is continuously removed.

This invention relates generally to a continuous process for producing coffee extract, and more particularly to a continuous process including decaffeinating coffee during the extracting process. This application is a continuationin-part of our application Ser. No. 342,043, filed Feb. 3, 1964.

Although a variety of processes have been developed over the years for the commercial production of soluble coffee, nearly all such processes have in common the batch extraction of ground roasted coffee, followed by separation of the grounds and drying of the resultant extract to recover the dissolved solids as a finely divided extract material. It is significant that, to date, not one truly successful continuous process has been developed by which controlled conditions of time, temperature, pressure and other process variables could be continuously maintained. The so-called continuous processes presently known in the coffee art generally involve the use of a battery of extractors, one or more of which is always being dumped or loaded while the others are on the line. Apart from substantial labor requirements, inconvenience and related problems associated with these essentially batch processes, such methods have proved incapable of providing the desired measure of control over process factors related to extraction emciency, flavor, and aroma, to make then entirely satisfactory for the intended purpose. Moreover, batch processes generally require the use of cracked coffee beans rather than ground coffee, to insure satisfactory operation of the batch percolators and related equipment. The coffee processor is consequently limited in his choice of starting materials, in the use of his equipment, and ultimately in his efforts to obtain optimum results.

Moreover, although it has been well known in the art to decaffeinate coffee, including coffee extracts, none of the previous methods have been carried out on a truly continuous basis. The solvent extraction of caffeine took place on a batch basis in the prior art.

The continuous process of the present invention tends to eliminate the undesirable features of known batch processes for producing decaffeinated coffee extract.

Our new concept, embodied in the continuous process of the present invention, effects a maximum extraction of coffee values from the original roasted coffee throughout the manufacturing process while retaining maximum taste and aroma constituents. It also permits a commercial operation wherein essential conditions of time, temperature, pressure, and through-put volume of extract liquid iti relation to roasted coffee solids can be optimally adjusted to insure the most successful commercial operation. Our new process provides the further advantage of extreme flexibility in the use of processing equipment, and thus facilitates the ready adjustment of such equipment to optimum conditions for various coffee types or blends. For example, we have particularly found that our new process can be employed to obtain a decaffeinated dried soluble concentrated coffee extract in a far more efiicient manner than the conventional batch processes employed heretofore. Moreover the present process is more flexible in that ground coffee as well as cracked coffee may be processed.

It is accordingly an object of this invention to provide a continuous process by which all the essential coffee values may be separated from roast ground coffee and caffeine in a rapid, controlled, economical manner, and in high yield.

Another object of the invention is to provide a continuous countercurrent process for producing a beverage extract of roast ground coffee wherein the coffee is countercurrently treated with aqueous liquid in a series of concurrent extraction operations, followed by countercurrent extraction of caffeine from the coffee extract.

Another object of the invention is to provide a continuous process of such character making use of aqueous slurries of the roast ground coffee, wherein such aqueous slurries are conveyed continuously through the treating or extraction operations.

Another object of the invention is to remove 97% of the caffeine present in coffee extract in a continuous, counter-current, liquid-liquid extraction process.

A further object of the invention is to provide an improved process for producing a beverage product of such character, wherein caffeine and undesirable flavor compone-tits are continuously removed and desirable flavor components are continuously restored to the end product.

A further object of the invention is to provide a process for continuously removing caffeine from the coffee extract while it is being processed.

Other objects and advantages of the invention will appear from the following description in which the preferred embodiment has been set forth in detail in conjunction with the accompanying drawings in which:

FIGURES 1 and 2 are flow sheets illustrating the general method of carrying out our continuous processing, with specific reference in FIGURE 1 to treatment of the roast ground coffee and in FIGURE 2 to the flow of extraction liquid;

FIGURES 3A, 3B and 3C form a schematic representation of a system of apparatus which may be used in carrying out the continuous processing in accordance with our invention; and

FIGURE 4 is a diagrammatic flow sheet generally related to the foregoing system of apparaus, but illustrating a slight variation in the processing.

Broadly, our new process for treating roast ground coffee to obtain a beverage extract makes use of a continuous, substantially countercurrent flow of process materials involving a series of successive extraction operations or steps to extract coffee values, and a caffeine extraction step to remove caffeine. In a particularly satisfactory embodiment of the invention, four such extraction operations or steps can be utilized in addition to the caffeine removal step. In the first step, fresh roasted ground coffee is extracted at atmospheric pressure with a coffee extract obtained from previously extracted roast coffee grounds. In the second step, the grounds are washed and again extracted at atmospheric pressure with a pressure extract obtained from previously extracted coffee grounds. In the third step, the twice extracted grounds are contacted under controlled conditions of temperature and pressure with 3 water which has bene in previous contact with spent coffee grounds. Finally, the resulting spent coffee grounds are contacted with fresh feed water in a washing operation. The aqueous extract recovered from these four steps is subjected to caffeine removal.

We have found that these continuous operations or steps are best carried out in concurrent extraction phases or unit operations wherein the coffee grounds move with the aqueous extraction liquids in the form of gently agitated, aqueous slurries. We have also found that extraction efliciencies can be somewhat improved through use of additional extraction steps. By way of illustration, further pressure extraction and Washing steps can be advantageously employed. In general, however, an optimum balance between product quality and yield is obtained through use of four coffee extraction steps, as outlined above.

Deoaffeination on the coffee extract may take place at any time after extraction from the grounds in the continuous extraction process. Because the caffeine solvent also tendsto dissolve volatile coffee constituents, We remove volatile coffee constituents from the coffee extract before the coffee extract is subjected to solvent extraction of caffeine. As is well known in the art, the volatile coffee constituents include the essential flavor elements of the roasted coffee. Loss of these volatile constituents by solvent treatment results in coffee lacking the desirable flavor of roasted coffee. Therefore the volatile flavor components are removed and condensed before caffeine is extracted, and thereafter the condensed volatiles are restored to the coffee extract. While caffeine extraction may take place at any convenient point in the continuous process after volatiles have been removed and before they are restored, it has been found advantageous to remove caffeine immediately prior to restoration of flavors and aroma to the coffee. Thus, removal of fine coffee muds and oils from the coffee slurry before caffeine removal substantially eases the maintenance problem in the caffeine extractor.

More specifically, as related to the flow of aqueous extraction liquid, our continuous process involves a series of distinct operations or steps which can be summarized as follows:

Contacting the spent coffee grounds from previous processing with feed water in a concurrent washing operation.

Separating and discharging the spent grounds from the wash Water.

Contacting previously washed and extracted coffee grounds with the wash water, in a concurrent extraction operation at elevated temperature and pressure.

Separating the resulting spent coffee grounds.

Contacting previously extracted coffee grounds with the foregoing pressure extract in a concurrent extraction and Washing operation at atmospheric pressure.

Separating the washed extracted coffee grounds for further use in the processing.

I Contacting fresh roast ground coffee with the foregoing wash liquor and pressure extract in a further concurrent extraction operation at atmospheric pressure.

Separating the freshly extracted coffee grounds for further use in the processing.

Processing the resultant extract liquid to remove caffeine from the aqueous extract to obtain the desired cofiee extract product.

In the continuous processing of the present invention, the above general operations or phases are carried out as Well defined and separated stages in which time, temperature and throughput volume of extraction liquid in relation to coffee solids can be optimally adjusted to insure the most successful operation. Moreover, although the process materials generally flow in countercurrent fashion, individual extraction phases or steps are carried out as essentially concurrent operations, except decaffeination, which is countercurrent, providing extreme flexibility to the overall processing and permitting use of various conventional techniques for flavor stabilization and recovery, concentration and/ or drying of the final aqueous extract.

An important aspect of this invention is the discovery that extraction of desired coffee values from roast ground coffee can be obtained in a rapid, controlled, economical manner, and in higher yield through use of aqueous slurries of the roast ground coffee with extraction liquids. Thus, the initial extraction of essential coffee values, in successive extraction stages at atmospheric pressure, can be best carried out by forming the roast coffee grounds into aqueous slurries with the extract liquids at the desired extraction temperatures. In like fashion additional coffee values can be obtained from the extracted cofiee grounds by movement of these grounds in the form of aqueous slurries with wash water or other extraction liquid through one or more pressure extraction steps, at controlled conditions of heat and pressure. Finally, the slurry technique has proved beneficial in the washing operation wherein the spent coffee grounds are washed in aqueous slurry with entering feed water to thereby extract and retain residual coffee values.

Referring to the drawings, FIGURE 1 represents a general flow sheet of our new process, and particularly illustrates the main steps in the continuous sequence.

In step 1, freshly roasted ground coffee: is initially extracted at atmospheric pressure, and at a temperature which is preferably optimum for brewing and flavor development. For most coffee blends, this optimum ordinarily occurs at a temperature of the order of F., although satisfactory results are obtained at temperatures ranging from about 170 F. to about 205 F. As will be apparent in FIGURE 1, the extraction in step 1 is carried out with the countercurrent flow of process water which has previously passed through washing and pressure and atmospheric extraction stages.

In step 2, the freshly extracted grounds are washed and again extracted at atmospheric pressure at substantially the temperature employed in step '1. This step is carried out with process water which has initially contacted with the spent grounds, and which has thereafter passed with the previously extracted grounds through a pressure extraction step. e

In step 3, the twice extracted grounds are subjected to continuous extraction at elevated temperature and pressure in a pressure extraction step. This step is optimally carried out at a temperature of the order of 360 F. and

under a pressure of the order of 140 p.s.i.g. However,

highly satisfactory results have been obtained at pressures ranging from 75 to 225 p.s.i.g., and at temperatures ranging from 320 to 400 F. During the extraction under pressure in step 3, additional coffee values are derived by the extraction liquid, which passes on to the extraction stages 1 and 2.

In step 4, the spent grounds from the pressure extraction are continuously washed with the entering process water, which removes residual coffee values from the spent grounds. In general, best results are obtained in the washing operation if the water has been heated to a temperature not higher than to F., although preheating is not absolutely essential.

In FIGURE 2, a flow sheet is given illustrating the continuous processing of our invention as related to the flow of extraction liquids. Thus, in step 10, the feed water is continuously mixed with the spent grounds discharged from the prior extraction treatments of the coffee grounds, to form an aqueous slurry. In step 11 the spent grounds are washed in a concurrent washing step to remove residual coffee values. This step corresponds to the washing step (i.e., step 4) in FIGURE 1. Following separation of the spent washed grounds in step 12, the wash liquid is mixed with previously extracted roast ground coffee to form a further aqueous slurry, in step 13. In step 14, this aqueous slurry is heated under pressure to hydrolyze and further extract the coffee grounds and thereby obtain an aqueous pressure extract. Step 14 thus corresponds to step 3 in FIGURE 1. The spent grounds are then separated in step 15 for further use in the processing as gen:

erally represented by the arrow 16. The extract liquid from the pressure extraction (step 14) is then mixed w th previously extracted roast ground coffee, in step 17, to again form an aqueous slurry. This slurry is heated in a concurrent extraction and washing step 18 to a desired extraction temperature (i.e., about 180 F.) to obtain an extract based on partially extracted roast ground coffee. The extracted grounds are next separated in step 19, and the extract mixed with the entering roast ground coffee, in step 29, to form a further aqueous slurry of fresh roast ground cofiee. This slurry is likewise heated in step 21 to the desired extraction temperature (about 180 F.) to obtain the final extract based on the fresh roast ground coffee. It may be noted that the sequence of heating prior to extraction in steps 18 and 21 is not critical, and in actual practice of the invention, it has proved advantageous to preheat the extraction liquids prior to the mixing in steps 17 and 20 to form an aqueous slurry. It is also contemplated that the roast cofiee introduced to step 20 may be preheated or be introduced at desired temperature directly from the roaster. Following this processing, the extracted roast coffee grounds are separated, in step 22, for return to the processing (arrow 23). The coffee extract is then subject to a caffeine removal step in which a solvent is used to separate the cafieine from the other coffee constituents. This step is indicated at 24. The final decaifeinated aqueous coffee extract may be utilized as is, concentrated, or dried to produce a dried coffee extract.

From the foregoing general description of the processing, and from the specific description hereinafter presented, it will be apparent that the final aqueous coffee extract contains all the essential coffee values normally obtained plus residual and pressure extracted values derived as an added benefit from the continuous processing, yet without any substantial amounts of caffeine. It will also be apparent that the desired coffee extract achieved by the processing Will be enriched in these coffee values, and therefore will be produced in higher yield than normally obtained in commercial extraction procedures. By way of illustration, we have found that the yield of dried cofiee extract from our continuous processing is approximately 25 to 35% greater than obtained with conventional batch processing and that decafiieination may take place at the same processing time without any substantial impairment in efficiency.

FIGURES 3A, 3B and 3C schematically illustrate a system of apparatus for carrying out our continuous process, and additionally illustrate certain refinements in the processing to achieve the most eificient extraction of coffee values while retaining taste and aroma constituents in substantially unimpaired form. As previously indicated, the processing is generally countercurrent, with the roast ground coffee entering the system at 30, and the process water entering at 32. However, the coffee grounds flow concurrently with the extraction liquids (in the form of gently agitated aqueous slurries) through the various extraction or operating phases of the process. With respect to the movement of coffee grounds, the main operating phases are indicated in FIGURE 3A to be an initial atmospheric extraction phase, a subsequent pressure extraction phase, and a final grounds washing phase. The illustrated operating phases generally correspond to the steps in the processing, outlined in FIGURE 1. Since these operating phases rely on circulation of the coffee grounds in the form of aqueous slurries, the apparatus employed in the separate operations or phases can be similar in general construction, for example, elongated treating vessels through which the slurries pass under a suitable hydrostatic or pressure head. Agitation means can also be employed within the various treating chambers to maintain the grounds and liquids phases in the desired slurry form.

Referring specifically to FIGURE 3A, fresh roast ground coffee is introduced to the system at 30 through a suitable feed hopper 34 and proportioning device 36 to a first atmospheric treating chamber or extractor 38. Within the extractor 38 the freshly ground coffee is subjected to a first atmospheric extraction at a temperature of about 180 F. and in the presence of efiiuent liquor from the washing and pressure extraction stages. The latter enters the extractor through the line 40 and conduit 42 and effects an initial turbulent mixing with the grounds within an inlet section 44 of the extractor to form the desired aqueous slurry. The slurry is maintained during its passage through the extraction chamber 38 by means of paddles rotated on the through shaft 46 by the motor 48. The extraction operation thus progresses continuously as the process materials flow concurrently through the extractor 38. The rate of flow of eifiuent liquor (and makeup water 50) through the extractor 38 is determined by suitable pump means 52, which discharge to a liquid-solid separation unit 53. The unit 53 separates the once extracted grounds from the extract liquor, allowing the latter to pass to a discharge line 54. The grounds are then mixed and formed into a slurry with elfiuent liquor from subsequent washing and pressure extraction stages in the mixing tank 55 and inlet section 56 of a second extractor 57, in the manner generally described in conjunction with the first extraction unit 33. As indicated in FIGURE 3A, this infiuent liquor can be preheated in the heat exchange unit 58 to a desired inlet temperature, say 180 to 200 F., to obtain a desired extraction temperature (i.e., 180 F.) within separate extraction units 38 and 57. Preferably steam jackets or other suitable heating means 59 are employed to maintain desired temperatures within the units 38 and 57 during the extraction phase. In keeping with the essential countercurrent operation described herein, the extraction liquid is separated in a second liquid-solid separation unit 60 for discharge to the line 40 leading to the first extractor 38. The extracted grounds are simultaneously discharged from the atmospheric extraction phase, at 61, for movement to the pressure extraction phase. The final extract liquor from the atmospheric extraction phase simultaneously passes through the line 54 for subsequent processing to produce the final coffee extract product.

The extracted grounds are next mixed in a slurry tank 62 with the effluent liquor from the washing phase to form a further aqueous slurry, This aqueous slurry is fed continuously to a high pressure feed pump 64, which discharges the slurry under pressure through a preheating unit 66, pressure extractor 6S, cooling unit '70, and discharge pump 72. The latter cooperates with the feed pump to maintain a desired pressure in the pressure extractor 68 (about 75 to 225 p.s.i.g.). The function of the heat exchange unit 66 is to facilitate maintenance of temperature conditions within the pressure extractor 68 by preheating the slurry to achieve a temperature of the slurry entering the pressure vessel within the range of from about 320 to 400 F., to effect a maximum extraction efiiciency within the pressure system. We have found, for example, that very satisfactory results can be obtained at a pressure of the order of p.s.i.g. and a temperature of 360 F. During this operation, the slurry in the extraction chamber 68 is gently agitated by the rotary paddle shaft 80 driven by the motor 82. Desired temperatures for the pressure extraction vessel 68 are maintained by either insulation or steam jacketing 69 or other suitable heat exchange means associated with a pressure extraction vessel. The intermixed spent grounds and pressure extract liquid leaving the pressure chamber are cooled in the heat exchange unit 70 to a temperature (e.g., to F.) suitable for discharge to the washing phase. Preferably, the slurry discharged by the pump 72 is fed to a further liquid-solid separating unit 74 which effects discharge of the spent grounds to the washer 76, and a separate discharge of the pressure extract liquid through the line 78 leading to the atmospheric extraction phase.

Following the pressure extraction phase, the spent extracted grounds are mixed with the process water entering at 32 in a mixing tank 8d, and the resulting aqueous slurry fed to the washer unit 76 under suitable hydrostatic head. The slurry moves through the unit 76 in the manner previously described to effect a thorough washing of the spent grounds. During this operation, the process water dilutes and remove-s residual coffee values remaining in the spent grounds. The slurry discharged from the washer 76 is separated in the unit 88, with the spent grounds being discharged at 90, and the wash liquid passing in countercurrent fashion to the pressure and atmospheric extraction phases described above.

So far, the use of the apparatus in the processing has been described with particular regard to the movement of coffee grounds. However, from the standpoint of the ultimate product produced, it is desirable to trace the flow of process water through the system of apparatus.

As indicated, the process water first effects washing of the spent grounds in the washer 76 to remove residuals and coffee values. It is then separated from the spent grounds in the separation unit 88 and conveyed by the pressure pump 92 to an extract clarification unit 94 where it picks up partially extracted fine coffee grounds or process muds separated from the final aqueous extract from the atmospheric extraction phase. These fines or muds have a particle size below about 300 microns, and therefore tend to pass through the screening units employed in the various liquid-solid separation units along with the extraction liquid phase. As indicated in FIGURE 3A, these process muds are mixed with the wash liquid in the tank 96 and flow with the wash liquid in the form of a fine suspension through the line 98. The muddy inflow through this line thus contains all the residual coffee values derived from the washing of the spent grounds and the intermixture with the mud at the extreme upstream end of the coffee grounds movement.

The muddy inflow from the clarifier 94 is next mixed with the extracted grounds from the atmospheric extraction phase in the slurry tank 62. The pressure extraction phase in the pressure units 66, 68 and 70 is thus carried out with an aqueous extraction liquid containing the residual coffee values from the washing phase. Following the pressure extraction operation and separation of spent grounds at 74, the muddy pressure extract is passed through the line 78, by means of the pump 100, to a second clarification unit 102. Here the fine spent coifee grounds, or muds are removed from the aqueous extract, prior to passage of the latter to the atmospheric extraction phase. Although the clarification unit 102 (and the unit 94) can be of any suitable type, the illustrated apparatus comprises a rotary filter dru-m maintained under internal vacuum. The aqueous phase thus passes to the interior of the filter drum and into the vacuum tank 104 for movement to the subsequent extraction operations. The muds, which form a filter cake on the exterior of the drum, are periodically discharged from the system as indicated by the arrow 106. The clarified pressure extract liquid is next passed to the pre-heater 58 for the atmospheric extraction unit by means of pump 108. In the preheater the aqueous mixture of pressure extract and residual coffee values is heated to the desired temperature for the atmospheric extraction phase (monitored by the control unit 110), and passes to the slurry tank 55 for the second atmospheric extractor 57. In the extractor 57, the liquid mixture effects an extraction of the entering roast coffee, previously extracted in the first extractor 38. The extract liquid now passes through the line 40 in the manner previously described to form a slurry with entering fresh roast ground coffee, at 44, following which it effects an initial extraction of the entering coffee in the extractor 38. The final aqueous extract from the atmospheric extraction phase is separated in unit 53, and passes through the discharge line 54 for further processing to achieve the final extract product.

As previously noted, the aqueous extract obtained from the atmospheric extraction phase (i.e., extractors 38 and 57) contains a substantial quantity of partially extracted fine coffee grounds or process muds which tend to flow with the extraction liquid phase. In accordance with the present invention, these process muds could be immediately separated in-the clarification unit 94, and the extract liquid subjected to drying to produce a dried extract product. However, in a preferred practice of the invention, the extract liquid is subjected to simultaneous processing to remove the volatile flavor and aroma components, to de-oil, concentrate, or otherwise process the nonvolatile extract, and to recombine all or part of the volatile components with the extract prior to spray drying to produce the desired soluble coffee product.

Referring specifically to FIGURE 3B, the final extract liquid in line 54, is fed to a flavor and aromaseparation phase, generally represented at 120. As illustrated, the flow of extract liquid is regulated by a suitable differential pressure sensing unit 122, controller 124, and flow control valve 126. The entering extract is next preheated in a suitable heat exchange unit 128, following which it is passed to a vaporiquid separator or flash tank 130 to eflect an initial separation of the volatile flavor and aroma components. The conditions in the vapor-liquid separator are carefully controlled to insure desired evaporation of a major portion of the volatile flavor and aroma components without production of discernible changes in color or flavor. The main extract passes from the bottom a of the flash tank 130 to a suitable heat exchange unit 132 to effect cooling of the nonvolatilized extract. The volatile components pass to a packed reflux or fractionating column 134, which operates in conjunction with a condenser unit 136 and a reboiler unit 138 which maintains the column in operation. The discharge line 140 from the condenser is provided with a proportioning valve 142 and return line 144 by which essence-enriched condensate is returned to the top of the fractionating column. The valve 142 can be controlled to maintain a suitable reflux ratio of flavor concentrate and recovery of the condensed volatile fraction through the line 146. In general, the flavor recovery unit can be of conventional design, for example, as described in Milleville' Patent 2,457,315, or by Walker and Patterson in the February 1957 issue of Food Technology. In a typical operation, the conditions in the flash tank 130 are such that the major proportion of the volatile components are removed by evaporation of from 5 to 30% of the extract liquid.

As indicated in FIGURE 3B, the recovered flavor and aroma components can be directly restored to the extract liquid (arrow 145), or, alternatively, can be mixed with the bottoms from the reflux column 134 (arrow 147) prior to restoration to the extract. In a further variation, the bottoms from the reflux column can be first mixed with the main effluent extract from the flash tank (arrows 148, 148) or they can be discharged from the system (arrow 149). V v

The effluent extract is next pumped through the, line 150 to the clarification unit 94 (FIG. 3A) Where the fine coffee grounds or process muds are separated for admixture with the wash water flowing through the pressure extraction phase. The clarified extract liquid is then pumped from the vacuum tank 151 of the clarifier through the line 152 to a tank 154. The extract can now be passed at a desired pressure in line (determined by the pump 156 and pressure relief line 158) to the centrifuge unit 162, where it is de-oiled, and to suitable storage tanks, represented by the tanks 164. As needed, the clarified, de oiled extract is pumped through line to conventional evaporating units 166 (FIG. 3C) where it can be concentrated to the desired solids content or used directly for caffeine extraction. We have found it desirable to employ the coffee extract at a solids content within the range of and 35%. At the upper end of this range, a greater quantity of coffee may be decaffeinated in a given amount of time, but we have found that the solvent tends to entrain coffee as well as to dissolve caffeine. At the lower end of the range of solids content, a much cleaner operation takes place, but a correspondingly greater amount of solvent is required for a given amount of decaffeination. Generally speaking, the aqueous extract supplied from storage tank 164 contains about 10 to solids content. Only when higher solids content is desired will the evaporator 166 be required. As a specific embodiment, with trichloroethylene as a caffeine solvent, we have employed a supply of 10 to 15 coffee solution from the storage tank 164, and preheated it in coffee preheater 207 to a temperature in the vicinity of 140 F. Heat exchanger 207 is equipped with a self-activated steam valve for thermostatic control at 140 F. The flow rate of the coffee stream is controlled and recorded by an orifice meter connected to a control valve 208. The coffee solution enters near the bottom of rotating disc column 2119, flows upward through the column, and collects in a quiet zone at the top where the phases separate. The location of the solvent-coffee solution interface is controlled by utilizing the differential densities of the liquids to activate a float switch connected to the outgoing solvent line. The interface controller in effect also controls the outgoing coffee stream. The decaffeinated solution passes from the caffeine extractor 209 to raffinate transfer pump 211 and in turn is passed to flash evaporator 212 for removal of entrained solvent. The decaffeinated extract then passes into storage tank 213 from which it is passed to the restoration station 170, as needed. Optionally, the decaffeinated extract may be concentrated in an evaporator (not shown) prior to restoration of volatiles. The extract is mixed in proper proportion with the recovered flavors and aromas at 170, following which the extract can be dried in conventional fashion in a spray drying unit 172 to produce the final soluble beverage product. In an alternative, the extract may be dried by freeze drying.

The solvent enters caffeine extractor 209 at the top, after being preheated in solvent preheater 214 which controls the temperature, in the case of trichloroethylene, at 140 F. The spent solvent is removed from the bottom of the caffeine extractor 209 and is passed through spent solvent pump 216 to spent solvent storage tank 217. From this tank the solvent passes to evaporator 218 for the purpose of solvent recovery. The caffeine remains in the evaporator bottoms from which it may be removed and purified. The evaporated solvent passes to condenser 219, and then to recovered solvent storage tank 221. As needed the solvent may be removed from storage tank 221 and recycled into the extraction system through pump 222. As needed, solvent make-up may be added to the storage tank.

In the processing of FIGURE 3, a single pressure ex traction stage is employed in conjunction with a two stage extraction at atmospheric pressures. However, the invention is not limited to any particular number of pressure or atmospheric extraction stages, and one or more extraction stages can be used in each instance with satisfactory results. We have particularly found that two extractions at atmospheric pressure, followed by two pressure extraction stages, provide a highly successful arrangement. Processing according to thisarrangernent is generally illustrated in diagrammatic form in FIGURE 4, which also provides a simplified representation of the overall process carried out by the system of apparatus schematically illustrated in FIGURES 3A, 3B and 3C. FIGURE 4 also illustrates a variation in the processing in that process muds from the atmospheric extraction phase are carried through the various stages of the pressure extraction phase, without intermediate clarification.

Referring to FIGURE 4, the roast ground coffee enters the system at 180, and is subjected to aqueous extraction in countercurrent fashion at atmospheric pressures, including a first extraction stage at 182 and a second extraction stage at 184. Thereafter the extracted grounds are subjected to a first pressure extraction at stage 186, in the presence of aqueous extract liquid containing process muds derived from the atmospheric extraction stages. The spent grounds are then washed at 188 and subjected to a second pressure extraction at stage 190, following which the spent grounds are washed at 192 and discharged from the system.

The process water in turn first contacts the grounds in the Washing operation at 192, following which it proceeds in generally countercurrent fashion through the second pressure extraction stage 190, wash operation at 188, and a mixing operation at 194 where it picks up the process muds from the initial aqueous extraction stages. The muddy extract liquid then flows through the first pressure extraction stage at 186, following which the muds are separated and discharged from the system. The resultant pressure extract then passes in generally countercurrent fashion through the second atmospheric extraction stage 184, and first extraction stage 182, Where most of the desired coffee values are removed from the entering roast ground coffee to produce the final aqueous extract.

In the processing of FIGURE 4, and specifically throughout each of the atmospheric extraction operations at 182 and 184, pressure extraction operations at 186 and 190, and the washing operations at 188 and 192, the extract liquids and coffee grounds move in concurrent fashion to thereby insure a desired prolonged intimate contact of the grounds and extract liquids consistent with maximum extraction efficien cies. The aqueous extract obtained from the first extraction stage 182 can be im mediately subjected to clarification to remove the fines or muds. Alternatively, it is subjected to processing to separate the volatile flavor and aroma components, as in the schematic flow sheet of FIGURES 3A, 3B and 3C. In general, the remaining operating stages shown in FIGURE 4 can be identical to those described in FIGURES 3B and 3C, wherein the nonvolatilized extract is clarified at 198 to separate the process muds, de-oiled at 200, concentrated at 202, and decaffeinated at 203 prior to mixing with the condensed volatile components at 204. Following mixing, the concentrated extract with restored flavor and aroma components can be discharged as a concentrated extract, or preferably, dried at 206 to produce a dried soluble beverage product.

In a typical operation according to our continuous process, and employing the system of apparatus generally disclosed in FIGURES 3 and 4, the operating conditions can be as follows:

Roast ground coffee is introduced at 30 at a rate of 1.78 pounds per minute. Process water is simultaneously introduced at 32 at the rate of 1.02 gallons per minute.

In the atmospheric extraction phase, the extraction liquid is preheated in the heat exchange unit 58 to a temperature of 190 F. to achieve an approximate inlet temperature to the second atmospheric extraction stage of F. This temperature is maintained in the second stage'extraction 57 and in the first stage extraction 38 by steam jacketing 59. The length of the extraction chambers 38 and 57 and the indicated rates of flow are such that the concurrent flow of extraction liquid and roast coffee grounds remains within each stage (in the form of gently agitated aqueous slurries) for a period of approximately 10 minutes. In the pressure extraction stage (extractor 68) the aqueous slurry of previously extracted grounds and muddy inflow of wash liquid is introduced at a pressure of 140 p.s.i.g. and a temperature of 360 F. The flow rates through the pressure extractor again achieve an extraction period of approximately 10 minutes duration. Where a second pressure extraction stage is used in FIGURE 4), identical extraction pressures, temperatures and flow rates can be employed. The cooling unit 70 reduces the temperature of the resulting aqueous slurry to approximately 180 R, which temperature is maintained as the grounds pass into the washing units. If desired, the process water entering at this stage can be preheated by a heat exchange unit (not shown) to a temperature of about 185 to 190 F. The clarification unit 94 is operated at a vacuum of approximately to 14 inches at vacuum within the filter drum, whereas the final clarification unit is operated at 5 to 9 inches vacuum. The final aqueous extract from the atmospheric extraction phase is introduced to the liquid-vapor separator 130, to efiect separation of the flavor and aroma components, at a rate of approximately 0.87 gallon a minute and at a temperature'of approximately 250 F. The liquid extract is discharged from the bottom of the separation unit 130 at a temperature of 195 F. The condensate is simultaneously passe-d to the proportioning valve 142 at a temperature of approximately 85 F. The ratio of condensed volatiles returned to the reflux column through the line'144, with respect to the proportion passing to the mixing tank 170, is approximately the same as originally present. That is, a pro rata restoration of volatiles to extract takes place. De-oiling is carried on in conventional fashion, and the de-oiled clarified extract passed to storage tanks at 164 at a rate of 0.66 gallon per minute. The extract liquid is evaporated in the unit 166 to achieve a desired concentration, following which the caffeine is removed in extractor 209. In the case of trichloroethylene, the ratio of solvent to water is preferably about 7.7: 1. With this solvent ratio,

. a caffeine removal of 98% is achieved. Flash evaporator 212 removes retained solvent and the condensed volatile flavor and aroma constituents are restored to the extract liquid pro rata. Spray drying is accomplished within the unit 172 at an air inflow of approximately 600 cubic feet per minute, preheated to a temperature of 440 F. The final soluble dried product is discharged at a temperature of about 185 F. and at a rate of 0.6 pound per minute.

As noted previously, the concentration of the aqueous extract may vary over a wide range during the decaffeination step. Thus, with trichloroethylene as the solvent we have found that a solids content within the range of 10 to 35% is operable. However, we have found that at solids content in excess of about 20%, the solvent-extract mixture tends to form an emulsion in the caffeine extractor. Although effective extraction takes place at solids content up to 30 to 35%, the spent solvent entrains undesirably large amounts of coffee. On the other hand, far less solvent is required when the solids content is at the maximum permissible percentage. In general, we have found that the solvent required is inversely proportional to the solids content of the coffee feed solution. In other words, about twice as much solvent is required for a solids content coffee feed solution as when a 30% coffee feed solution is used. Thus, at an optimum solids content of about 12%, considerably more solvent is required than at higher concentrations. Although, must less coffee is entrained in the solvent at' 12% solids content, the greater amount of solvent demands the use of larger solvent storage tanks and a greater supply of solvent in the system.

Solvents for the removal of caffeine are well known in the art. A number of these solvents have been evaluated and have been found satisfactory for use in our continuous process. Such solvents include ethylene dichloride, carbon tetrachloride, chloroform, trichloroethylene and trichloroethane. While chloroform appears to provide the most effective caffeine extraction, it presents certain hazards in use. Trichloroethylene is preferred for use as the solvent because it tends to provide the lowest losses of coffee solids due to precipitation, and to cause practically no change in the pH of the coffee solution. A further important advantage of trichloroethylene is that it forms no stable emulsions under a wide range of operating conditions.

The temperatures at which caffeine removal takes place is dependent upon the particular solvent employed. We

have found that a temperature somewhat below the boiling point of the solvent is effective for caffeine removal. In the case of trichloroethylene (B.P. 189 F.) it has been determined that F. is optimum. On the otherhand, with chloroform (B.P. 142 F.) a much lower temperature must be employed in the caffeine removal step. About 20 to 70 degrees below the boiling point of the solvent is the preferred range for decaffeination tempe'raturef Thus, with the solvents tested which boil at temperatures ranging from 142 F. (chloroform) to 236 F. (1,1,2- trichloroethane) the temperature in the caffeine extractor should be between 70 F. and 215 F.

A variety of extraction equipment may be employed to remove caffeine. Column-type continuous counter:

current liquid-liquid extractors are generally preferred because they are easier to construct, operate, and maintain. However, in the case of systems which emulsify readily, mixer-centrifuge type equipment is to be preferred. Spray type columns may also be used, but are gen erally subject to the disadvantage that excessive column height is required for desired extraction efliciencies.

Packed columns may also be used, although the deposition of insoluble coffee solids on the packing may present a maintenance problem.

We have found a preferred caffeine extractor to. comprise a rotating disc column, in which a tube is filled with numerous baffled compartments. The horizontal baflles are supported on vertical rods held in tension. Holes are cut in the center of each baflle, and a shaft containing impellers is mounted in the holes of the batlies within the tube. The impellers are flat metal discs which are mounted at the center of each compartment on a rotating shaft. The shaft may advantageously be equipped with a variable speed drive. We have found that the rotating disc column has less tendency to cause entrainment or emulsification and can therefore accommodate higher flow rates.

If desired, the calfeine which is removed from the solvent (e.g., at evaporator. 218) may be recovered, and the operating cost of the decalfeination process. reduced by sales of the recovered caffeine. Methods for purifying the crude caffeine recovered from the solvent will depend primarily on market requirements such as color andpurity of product. The caffeine may be purified by sublimation, or, preferably, by recrystallization combined with decolorization by activated carbon.

The dried soluble coffee product produced by the above contlnuous processing was found to be higher in aroma than commercially available soluble coffee products produced by conventional batch processes. It also possessed an enhanced flavor, and was free of 97% of the caffeine. In addition, the processing has proved particularly advantageous in that the processing conditions can be easily controlled, extraction efficiencies and yields are improved, and the processing in every case produces a final product having enhanced flavor and aroma, as well as improved shelf life and storage characteristics.

Many variations are possible in the processing herein described, and in the use of the exemplary systems of apparatus disclosed. For example, while the preferred decatfeination step takes place immediately prior to restoration of flavors and aroma, it is possible to carry out decatfeination immediately after de-oiling at centrifuge. 162 and before storage in tanks 164. This would permit storage tanks 164 to be employed as decaffeinated extract storage tanks.

Many other variations will similarly occur to those skilled in this art, and can be'easily adapted to the disclosed continuous process and system of apparatus without changes in the overall concept of the processing. Accordingly, it should be understood that the disclosures herein areintended as purely illustrative, and not in any sense limiting.

We claim:

1. In a continuous process for producing a beverage extract from roast ground coffee, the successive steps of intermixing spent extracted roast coffee grounds with water to form an aqueous slurry, causing said slurry to move in a concurrent Washing operation to effect extractions of residual coffee values from said spent grounds, separating and removing the spent coffee grounds, intermixing the wash liquid from said washing operation with previously extracted roast coffee grounds to form a second aqueous slurry, causing said second aqueous slurry to move in a concurrent extraction operation while subjecting the same to elevated temperature and pressure to thereby obtain an aqueous pressure extract of said previously extracted coffee, separating the resulting spent grounds from said pressure extract, intermixing said pressure extract with previously extracted coffee grounds to form a third aqueous slurry, causing said third slurry to move in a concurrent washing and extraction operation While at elevated temperature to thereby obtain an aqueous extract of said previously extracted coffee grounds, intermixing said aqueous extract with fresh roast ground coffee to form a fourth aqueous slurry, causing said fourth slurry to move in a concurrent extraction operation while at elevated temperature to thereby obtain an aqueous ex tract said last named extraction step being carried out at a temperature below that which would adversely affect the final decaffeinated extraction product, and removing caffeine from said extract.

2. A process as in claim 1 wherein said concentrated aqueous coffee extract is dried to form a substantially dry soluble caffeine-free product.

3. In a continuous process for producing a beverage extract from roast ground coffee, the successive steps of intermixing spent extracted roast coffee grounds with water to form an aqueous slurry, causing said slurry to move in a concurrent Washing operation to effect extraction of residual coffee values from said spent grounds, separating and removing the spent washed coffee grounds, intermixing the wash liquid from said washing operation with previously extracted roast coffee grounds to form a second aqueous slurry, causing said second aqueous slurry to move in a concurrent extraction operation while subjecting the same to elevated temperature and pressure to thereby obtain an aqueous pressure extract of said previously extracted coffee, separating the resulting spent grounds from said pressure extract, intermixing said pressure extract with previously extracted coffee grounds to form a third aqueous slurry, causing said third slurry to move in a concurrent washing and extraction operation while at elevated temperature to thereby obtain an aqueous extract of said previously extracted coffee grounds, intermixing said aqueous extract with fresh roast ground coffee to form a fourth aqueous slurry, causing said fourth slurry to move in a concurrent extraction operation while at elevated temperature to thereby obtain an aqueous extract, said last-named extraction step being carried out at a temperature below that which would adversely affect the final decaffeinated extraction product, separating the extracted coffee grounds from said aqueous extract, separating volatile extract components from said aqueous extract, removing caffeine from the remaining non-volatile aqueous extract, condensing said volatile components, and recombining the condensed volatile components with the aqueous extract to form a final decaffeinated coffee extract.

4. In a continuous process for producing a beverage extract from roast ground coffee, the successive steps of intermixing spent extracted roast coffee grounds with water to form an aqueous slurry, causing said slurry to move in a concurrent washing operation to effect extraction of residual coffee values from said spent grounds, separating and removing the spent washed coffee grounds, intermixing the wash liquid from said washing operation with previously extracted roast coffee grounds to form a second aqueous slurry, causing said second aqueous slurry to move in a concurrent extraction operation while subjecting the same to elevated temperature and pressure to thereby obtain an aqueous pressure extract of said previously extracted coffee, separating the resulting spent grounds from said pressure extract, intermixing said pressure extract with previously extracted coffee grounds to form a third aqueous slurry, causing said third slurry to move in a concurrent Washing and extraction operation while at elevated temperature to thereby obtain an aqueous extract of said previously extracted coffee grounds, intermixing said aqueous extract with fresh roast ground coffee to form a fourth aqueous slurry, causing said fourth slurry to move in a concurrent extraction operation while at elevated temperature to thereby obtain an aqueous extract, said last-named extraction step being carried out at a temperature below that which would adversely affect the final decaffeinated extraction product, separating the extracted coffee grounds from said aqueous extract, separating volatile extract components from said aqueous extract, condensing said volatile components, removing excess water from the remaining aqueous extract to concen trate the same, removing caffeine from said concentrated extract, and recombining the condensed volatile components with the concentrated aqueous extract to form a final decaffeinated concentrated coffee extract.

5. In a continuous process for producing a beverage extract from roast ground coffee, the successive steps of intermixing spent extracted roast coffee grounds with water to form a aqueous slurry, causing said slurry to move in a concurrent washing operation to effect extraction of residual coffee values from said spent grounds, separating and removing the spent washed coffee grounds, intermixing the wash liquid from said washing operation with previously extracted roast coffee grounds to form a second aqueous slurry, causing said second aqueous slurry to move in a concurrent extraction operation while subjecting the same to elevated temperature and pressure to thereby obtain an aqueous pressure extract of said previously extracted coffee, separating the resulting spent grounds from said pressure extract, intermixing said pressure extract with previously extracted coffee grounds to form a third aqueous slurry, causing said third slurry to move in a concurrent washing and extraction operation while at elevated temperature to thereby obtain an aqueous extract of said previously extracted coflee grounds, intermixing said aqueous extract with fresh roast ground coffee to form a fourth aqueous slurry, causing said fourth slurry to move in a concurrent extraction operation while at elevated temperature to thereby obtain an aqueous extract, said last-named extraction step being carried out at a temperature below that which would adversely affect the final decafleinated extraction product, separating the extracted coffee grounds from said aqueous extract, sepa rating volatile extract components from said aqueous extract, continuously removing caffeine with a caffeine solvent by countercurrent extraction, condensing the separated volatile components, and recombining the condensed volatile components with the decaffeinated aqueous extract to form a final decaffeinated coffee extract.

6. In a continuous process for producing a beverage extract from roast ground coffee, the successive steps of intermixing spent extracted roast coffee ground with Water to form and aqueous slurry, causing said slurry to move in a concurrent washing operation to effect extractions of residual coffee values from said spent grounds, separating and removing the spent coffee grounds, intermixing the Wash liquid from said washing operation with previously extracted roast coffee grounds to form a second aqueous slurry, causing said second aqueous slurry to move in a concurrent extraction operation while subjecting the same to elevated temperature and pressure to thereby obtain an aqueous pressure extract of said previously extracted coffee, separating the resulting spent grounds from said pressure extract, intermixing said pressure extract with previously extracted coffee grounds to form a third aqueous slurry, causing said third slurry to move in a concurrent washing and extraction operation while at elevated temperature to thereby obtain an aqueous extract of'said previously extracted coffee grounds, intermixing said aqueous extract with fresh roast ground coffee to form a fourth aqueous slurry, causing said fourth slurry to move in a concurrent extraction operation while at elevated temperature to thereby obtain an aqueous extract, said last-named extraction step being carried out at a temperature below that which would adversely affect the final decaffeinated extraction product, continuously extracting caffeine by liquid-liquid counter-current extraction with a caffeine solvent.

7. A process as in claim 6 wherein said continuous caffeine extraction is carried out using trichloroethylene to extract caffeine from said aqueous extract.

8. A process as in claim 6 wherein said aqueous extract is introduced into the bottom of a rotating disc column to counter the flow of caffeine solvent introduced into the topof the column to extract caffeine.

9. A process as in claim 8 wherein the solvent bearing the extracted caffeine is continuously recovered.

10. In a continuous process for producing a beverage extract from roast ground coffee, the successive steps of intermixing spent extracted roast coffee grounds with water to form an aqueous slurry, causing said slurry to move in a concurrent washing operation to effect extractions of residual coffee values from said spent grounds, separating and removing the spent coffee grounds, intermixing the wash liquid from said washing operation with previously extracted roast coffee grounds to form a second aqueous slurry, causing said second aqueous slurry to move in a concurrent extraction operation while subjecting the sameto elevated temperature and pressure to thereby obtainv an aqueous pressure extract of said previously extracted coffee, separating the resulting spent grounds from said pressure extract, interrnixing said pressure extract'with previously extracted coffee grounds to form a third aqueous slurry, causing said third slurry to move in a concurrent washing and extraction operation while at elevated temperature to thereby obtain an aqueous extract of said previously extracted coffee grounds, intermixing said aqueous extract with fresh roast ground coffee to form a fourth aqueous slurry, concurrent extraction operation while at elevated temperature to thereby obtain an aqueous extract, said lastnamed extraction step being carried out at a temperature below that which would adversely affect the final decaffeinated extraction product, continuously removing caffeine from said extract, continuously recovering said removed cafieine, and continuously purifying said recovered caffeine. 7

11. A process as in claim 6 wherein said caffeine extraction takes place at a temperature somewhat below the boiling point of said caffeine solvent.

References Cited UNITED STATES PATENTS 2,522,014 9/1950 Bacot 99-71 2,915,403 12/1959 Clinton et al 997 1 2,933,395 4/1960 Adler et al 99-70 X 3,148,069 9/1964 Sjogren et al 99-71 OTHER REFERENCES Sivetz, M.: Coffee Processing Technology, vol. 2, Aoi Pub. Co., Westport, Conn, 1963, p. 209.

MAURICE W. GREENSTEIN, Primary Examiner.

causing said fourth slurry to move in a Alvarez 99 2s9 

